Ice PegasusHS, Service Manual

Page 1: ...PegasusHS Service Manual P N 361854 21 Revision AA November 2006 ...

Page 2: ... and contains confidential and proprietary information owned by ICE Any unauthorized copying use or disclosure of it without the prior written permission of ICE is strictly prohibited ICE interactive coding equpiment Phone 01159 640144 Fax 01159 639317 Olympic House Willow Drive Sherwood Park Nottingham NG15 0DP www interactivecoding com ...

Page 3: ...ful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference In such cases the users will be required to correct the interference at their own expense Shielded cables must be used with this unit to ensure compliance with Class A FCC limits The user may find the following booklet prepared by the Federal Communications Commission ...

Page 4: ...ls numerique de las class A prescrites dans le Reglement sur le brouillage radioelectrique edicte par le ministere des Communications du Canada Cet équipement est certifié CSA For Customers in the European Union This equipment displays the CE mark to indicate conformance to the following legislation EN55022 1998 EN55024 1998 EN61000 6 2 2001 FCC CFR 47 parts 15 107 and 15 109 ...

Page 5: ...TOTAL SERVICE PLUS RELIABILITY is the ICE commitment to provide you our customer the complete service you deserve The Total Source Commitment The ICE Service Program is an integral part of our business in providing marks codes and images where when and how often customers specify for packages products or printed materials Our commitment includes Applications support Installation services Maintenan...

Page 6: ...he printer ICE highly recommends that you complete a Customer Training Course on the printer Note The manuals are intended to be supplements to and not replacements for ICE Customer Training For more information on ICE Customer Training Courses call 01159 640144 ICE Pegasus Service Manual ...

Page 7: ...s 1 3 Safety Guidelines 1 4 Comply with Electrical Codes 1 4 Do Not Remove Warning Labels 1 5 Placement of the Printer 1 5 Using Printer Accessories 1 5 Chapter 2 Introduction Equipment Description 2 1 About this Manual 2 2 Related documents 2 2 Theory of Printing 2 3 Intermittent Motion Printing 2 3 Continuous Motion Printing 2 4 Chapter 3 Technical Description Unpacking the Printer 3 1 Installin...

Page 8: ...e Inputs 3 25 The Outputs 3 25 Default Options Configuration 3 26 Chapter 4 CLARiTY Operating System Getting started with the CLARiTY 4 1 Using the Tools Page 4 2 Working with Setup Page 4 3 Working with Diagnostics 4 8 Working with Passwords 4 25 Password Protection Set up 4 26 Chapter 5 Maintenance Maintaining the Power Supply 5 2 Replacing the Mains Fuse 5 2 Maintaining the CLARiTY Controller 5...

Page 9: ...rated Parts List How to Read the IPL 8 1 Illustrations 8 1 Alphabets 8 2 Numbers 8 2 Tables 8 3 Controller Assembly 8 4 Printer Assembly 8 5 Printhead Assembly 8 5 Cassette Assembly 8 7 Accessories 8 8 Printer Ribbons 8 9 Chapter 9 Drawings Printer Dimensions 9 1 Electrical Wiring Schematics 9 4 ICE Pegasus Service Manual ...

Page 10: ... is to manufacture printing coding systems and supplies that meet high standards of performance and reliability Therefore we employ strict quality control measures to eliminate the potential for defects and hazards in our products The intended use of this printer is to print information directly onto the product Use of this equipment for any other purposes may lead to serious personal injury The s...

Page 11: ...ntenance personnel should perform these installation procedures Qualified personnel have successfully completed the training courses have sufficient experience with this printer and are aware of the potential hazards to which they may be exposed Warning PERSONAL INJURY Before attempting any maintenance or repair on any part of the product disconnect the printer from the main power supply and isola...

Page 12: ...printer to other equipment must be limited to no greater than 50 V DC or peak AC Warning ELECTRICAL HAZARD Always wear a properly ground wrist ground strap when handling printed circuit boards Failure to do so can result in damage to the board components due to static electricity General Caution Notices The following caution statements supplement the specific cautions that appear elsewhere in the ...

Page 13: ...and such damage is not covered by your printer warranty Use only ribbon approved by your dealer Safety Guidelines This section contains important safety guidelines pertaining to the operation and handling of the printer and associated equipment Warning SAFETY GUIDELINES Always observe the following safety guidelines when operating and handling the printer and associated equipment Comply with Elect...

Page 14: ...ations as defined in the United States are those areas that may contain hazardous materials in a quantity sufficient to create an explosion These are defined in Article 500 of the National Electrical Code ANSI NFPA 70 1993 Outside the United States you must ensure compliance with all local regulations regarding equipment placement in potentially hazardous locations Using Printer Accessories To mai...

Page 15: ...ermal transfer technology with a unique electronic ribbon drive system The printer offers greater reliability and ease of operation compared to earlier systems It can print barcodes dates text and graphics onto flexible packaging films and labels The printer is a suitable replacement for either hot stamp or rotary printers It can print in either of the following modes Intermittent Mode i e while t...

Page 16: ...t 6210 Operator Manual P N 361853 is intended for the operator and contains information on routine operation of the printer Unless specified all procedures in this manual can be performed by the operator of the printer It is mandatory that the personnel read the Operator Manual before reading the Service Manual This manual is a supplement to and not a replacement for formal training Warning PERSON...

Page 17: ...he printhead and the substrate move relative to each other The print elements are programmable and controlled to create an image Intermittent Motion Printing Intermittent motion printing Figure 2 2 on page 2 4 is the concept used for printing on stationary packaging films in packaging equipment that has a start stop action each time a product is packed Such applications can be found in intermitten...

Page 18: ...d Such applications can be found in Continuous Vertical Form Fill Seal VFFS and Horizontal Form Fill Seal HFFS or flow wrap machines Continuous motion printing has the following features The substrate moves while the printhead is stationary Speed of the substrate is monitored by an encoder The ribbon and the substrate speeds are matched by the ribbon drive The printhead presses against a rotating ...

Page 19: ...v AA Theory of Printing 2 5 1 2 3 4 RIBBON FEED MATERIAL FEED 1 Ribbon Transfer Carbon Print 2 Platten Roller 3 Substrate 4 Thermal Printhead Figure 2 3 Continuous Print Motion ICE Pegasus Service Manual ...

Page 20: ... the Power On Understanding Printhead LEDs Configuring the Printer Working with the Configurable Inputs and Outputs Unpacking the Printer Inspect the kit for any damage carefully Refer the list of parts in Table 3 1 and Figure 3 1 on page 3 2 If any item is damaged or missing call ICE Customer Service Department at 01159 640144 Printer Part Printer Cassette CLARiTY Controller Air Regulator Power C...

Page 21: ...ate Printer Part Table 3 1 Printer Configuration Parts List Continued 1 Air Regulator 2 4mm Air Tubing 3 CLARiTY Controller 4 CLARiTY Controller Bracket 5 Power Cord 6 Printer 7 I O Low Profile Cable Assembly 8 Cassette 9 CLARiTY Configuration Manager CD ROM Figure 3 1 Printer Configuration Parts 1 2 3 4 5 6 7 8 9 ICE Pegasus Service Manual ...

Page 22: ...t act against a flat print platen in an intermittent mode or a print roller in a continuous mode in order to print The platen or roller is a part of the mounting bracketry Printer The printer can be mounted in any orientation However it is important to ensure that adequate operator access is available to remove and replace the cassette easily The exact position of the printer relative to the packa...

Page 23: ...s M6 Tapped Holes Thread Depth 6 00 3 Places 20 73 mm 2 PLCS 167 15 mm 185 30 mm 158 00 mm Printhead Retracted 162 50 mm 25 70 mm 32 50 mm 1 28 inches 157 80 mm 159 60 mm 26 20 mm 32 00 mm Printable Area Figure 3 2 Videojet 6210 30 mm RH Printer Dimensions 7 3 inches 6 58 inches 164 00 mm 6 46 inches 1 01 inches Printhead Stroke 6 4 inches 6 22 inches 6 23 inches 6 21 inches 1 03 inches 1 26 inche...

Page 24: ...e printer Figure 3 4 CLARiTY Controller The CLARiTY operator interface can be mounted at a convenient location so that the operator has adequate access to the panel The CLARiTY controller has a built in power supply unit The unit has two M6 mounting holes located at the sides of the unit as shown in Figure 3 5 on page 3 6 Figure 3 4 Printer Pad or Roller Position Printer Pad or Roller 158 mm 164 m...

Page 25: ...maximum lead length of 9 8 ft 3 m is not exceeded The mounting brackets provided allow you to position the controller against a convenient vertical flush surface Figure 3 5 CLARiTY Controller Dimensions 69 20 mm 208 35 mm 191 25 mm 41 00 mm M6 Female Thread Both Sides Thread Depth 6 00 96 90 mm 118 90 mm 4 68 inches 8 2 inches 7 53 inches 3 81 inches 2 72 inches 1 61 inches ICE Pegasus Service Man...

Page 26: ...hecking the correct pressure of 3 bar Encoders An encoder is used to match the printing speed to the speed of the target material as it passes the printhead Use the Encoder Kit part number 403358 for these applications The encoder must ideally be mounted to run on the packaging film close to the printer in order to accurately measure the film speed Any discrepancy between measured and actual film ...

Page 27: ...ch a damage is not covered by your printer warranty Use only the ribbon that is approved by your dealer To install the ribbon proceed as follows 1 Remove the cassette Figure 3 6 2 Put the cassette down on a flat surface with the ribbon spools Item 1 Figure 3 7 on page 3 9 facing upwards and the ribbon rollers Item 2 towards you Figure 3 6 Cassette Removal ICE Pegasus Service Manual ...

Page 28: ...uated under each spool can be used to lever the spool off the cassette 4 Discard the used ribbon and the spools 5 Open a new shrink wrapped roll of ribbon and unwind about 12 inches 30 cm of ribbon The spool holders on the cassette have different color discs Figure 3 7 Cassette Removed 1 Ribbon Roller x2 2 Ribbon Spool x2 1 2 Figure 3 8 Ribbon Spools Removal ICE Pegasus Service Manual ...

Page 29: ...e roll should be located such that the ribbon unwinds in the direction as shown in Figure 3 9 Note Ensure that the spool is pushed completely down onto the holder 7 Route the ribbon so that it Unwinds from the outside of the full roll Goes around the outside of the white roller that is nearest to the full roll Runs along the bottom of the cassette Goes around the outside of the second white roller...

Page 30: ...p any excess ribbon Stop turning the empty spool when the full spool starts to rotate Figure 3 11 Note If the supplied ribbon has a transparent section or printed leader at the start rotate the empty spool to take up all the transparent ribbon 10 Insert the cassette into the printer body Figure 3 10 Ribbon Spool Complete Figure 3 11 Ribbon Spool Routing ICE Pegasus Service Manual ...

Page 31: ...inthead Setting the pressure too low can cause poor print quality Working with Printer Connections Product Sensors Print Signals One 15 pin D Type male connector located on the side of the printer is dedicated for input and output connections The printer can be triggered to print either by a mechanical contact print signal or a 24 V DC PNP product sensor The printer can be configured to print eith...

Page 32: ...NP Sensor Wiring Print Sensor 1 1 PNP Sensor 2 15 pin Male D type Connector 2 1 9 SIG 8 24VDC 15 0V Figure 3 13 Mechanical Contact Wiring Print Sensor 2 1 1 Print Signal Relay Contact 2 15 pin Male D type Connector 1 9 SIG 8 24VDC 15 ICE Pegasus Service Manual ...

Page 33: ... encoder enables the printer to react if the packaging material is traveling backwards This prevents the occurrence of breaks in the ribbon and possible damage to the printer The use of a quadrature mode encoder is obligatory Note These settings are known as configuration settings and cannot be set at the CLARiTY panel For further information refer Configuring the Printer on page 3 19 Figure 3 14 ...

Page 34: ... the input and output connections Note For more information on configuring the inputs and outputs refer Working with the Inputs and Outputs on page 3 25 Pin Purpose 1 24 V 2 External input 1 PNP 24 V 3 0 V 4 External input 2 PNP 24 V 5 Not Used 6 Relay output 1 N C 7 Relay output 1 common 8 Relay output 1 N O 9 Relay output 2 common 10 Relay output 2 N O 11 PNP 24 V Output 1 12 0 V 13 Not Used 14 ...

Page 35: ...ement Software such as the CLARiSOFT for VJ6210 Image Design Software P N 703490 CLARiTY is supplied with some default images installed in its database memory CLARiTY can be configured to work in the following mode Standalone Mode Download images to CLARiTY using a standard PC null modem cable twisted 9 pin D type female to female connected between PC COM1 port and CLARiTY RS232 port cable supplie...

Page 36: ...rking with Printer Connections 3 17 Figure 3 15 Videojet 6210 Cable Connections D25 M Low Profile Connector Encoder Mains Power Air PRINTER RS232 D9 F 15 Way I O Cable Unterminated USB ICE Pegasus Service Manual ...

Page 37: ...ring which the printer calibrates the ribbon drive The status bar flashes the words STARTING UP and the amber LED flashes on and off When the process is complete the home page changes as follows The CLARiTY status panel changes from STARTING UP to OFFLINE The Consumables area displays the percentage of ribbon remaining In the Control Frame the Start and Stop buttons are enabled The blue Power LED ...

Page 38: ...efault configuration is ideal This can lead to a large and cumbersome Menu Tree on the printer s controller that users have to work with Most printer variables are set during the installation process The variables are set to values that tailor the printer to the application Once set these variables only need to be changed when the application for the printer changes As such there is no need to mak...

Page 39: ...unctionality Snapshot of CLARiTY screens As a result the CLARiTY Controller only retains the availability of a small number of operating variables for the user to change Apart from making the CLARiTY control system more simple and user friendly it also provides an increased level of printer system integrity because the configuration variables cannot be accessed from the printer itself but only fro...

Page 40: ...Click the Start button 2 Click the Run button to open a dialog box 3 Type D setup exe in the dialog box and press enter return key Note D is the drive letter of the PC s CD ROM drive If it is different for your PC replace the letter D with the appropriate drive letter The software is installed in the PC and is ready for use Connecting the CLARiTY Configuration Manager to the Printer Connecting CLA...

Page 41: ...er applications running on the PC that are using the serial port Check that the baud rate settings on the Configuration Manager matches with the printer s baud rate 4 Click the Upload button The progress of the operation is displayed in the status pane This uploads the printer parameters set to the PC The list of folders containing the configuration parameters appears in the parameter listing in t...

Page 42: ...1 Click the required parameter from the parameter list The current value is displayed in the Value box at the bottom of the screen 2 Change the value to the required value using the mouse and the keyboard 3 Click the Apply button The value displayed in the parameters list is updated to reflect the change Note Event parameters do not have values that can be set Touching the Trigger button that is a...

Page 43: ...ete Note Unless steps 1 to 4 are performed none of the parameter changes become effective in the printer Archiving the Current Parameters The set of parameters can be saved as an archive and are stored on the PC The archive can be loaded into the Configuration Manager and downloaded to the printer again at a later date to revert to the archived set of parameters Once the printer has been configure...

Page 44: ...the packaging line The Inputs The inputs are pre configured as Print Sensor Using a 24 V PNP input to trigger the printer to start printing Inhibit Print Using a 24 V PNP input to inform the printer that the host packaging machine or line has an error and the printer should not print Spare Input 1 Not Available for Use Repeat the steps 1 to 5 for all the three inputs and then download the paramete...

Page 45: ...the outside of a bag Devices Phds 1 Image Information Print Orientation None Degre es 0 Rotates all selected images through 180 degrees Reset Image Sequence On Offline None None Yes When using a sequence of print images this parameter forces the sequence to reset back to the start when the printer goes offline Devices Phds 1 Print Information Continuous Auto Print Triggering None None No Allows in...

Page 46: ...ints per Signal None None 1 The number of prints per print signal when using Continuous Multi Print Mode Devices Phds 1 Print Information Continuous Registration Delay Horizontal Registration mm 0 The distance to delay the print after receipt of the print signal In Con ti no us Multi Print Mode this defines the distance to the first print Continuous Repeat Distance None mm 100 The distance between...

Page 47: ...rint pad Devices Phds 1 Print Information Maximum Re Print Gap None mm 40 If the Low Speed Behavior is set to Resume on Speedup then if the bag moves a distance greater than this parameter whilst in low speed the coder prints a complete whole code on the bag as soon as the film speed exceeds 65mm s Print Darkness Print Darkness 75 Sets the amount of energy being sent to the printhead Devices Phds ...

Page 48: ...e film distance is advanced Works in conjunction with Print Sensor Debounce Time the first to expire wins Using the distance method of debouncing guarantees print registration the time based system doesn t Devices Phds 1 Print Information Print Speed Print Speed mm per sec 200 The print speed to be used in intermittent mode printing Printer Hand Printer Hand None No default requires setting LH or ...

Page 49: ...age across the width of the printhead Profiler Capture Encoder Profile Capture Encoder Profile None None Triggers the capturing of an encoder profile Imaging Printhead Mapping None None Printhead 1 Required parameter do not adjust Printer Codes Factory ID None None 1 Allows the setting of a unique special code for the Factory ID It is a global setting for the printer and all layouts that reference...

Page 50: ...led Operations Cycle Head Position None None None Cycle moving the printhead from its parked position to its printing position Cycle Print None None None Cycle the unit printing continuously Generate Log Files None None None Triggering this Operation will cause log files to be generated in the Log File Folder within the coder These files would be requested by Technical Support in the event of the ...

Page 51: ...LARiTY Passwords Enable Passwords None None Disabled Enables or disables password protection If enabled the 3 levels of passwords must be set up using the following 9 parameters Level 1 Mask None None None Check which functions are to be available to Level 1 users Level 1 Name None None None The name of a level 1 user e g Operator Level 1 Password None None None The password for level 1 numeric on...

Page 52: ...ne Yes When a USB memory stick is inserted and USB is enabled CLARiTY automatically runs the CLARiTY update if there is a valid file on the stick When the USB is disabled the user has to manually initiate the action from the CLARiTY screen Re calibrate Touchscreen Re calibrate Touchscreen None None Triggers re calibration of the touchscreen User Interfaces Set Screen Contrast To Default None None ...

Page 53: ...s of the display are active that is touching an area on the screen is like pressing a button on a traditional control panel The basics of the CLARiTY operator system are explained in the Videojet 6210 Operator Manual P N 361853 All technical aspects of the printer setup and control are accessed through the Tools button Figure 4 1 shows the home screen of the CLARiTY operator sytem Figure 4 1 CLARi...

Page 54: ...he tools page allows you to access the following pages Setup page Permits you to modify a small subset of the printer setup parameters Diagnostics page Provides on line fault finding routines and diagnostic functions Databases page Provides control over the jobs database of the coder Figure 4 2 Tools Page ICE Pegasus Service Manual ...

Page 55: ...button on the tools page to access the setup page Figure 4 3 The Setup page allows you to access the following parameters Printhead and printing operations Consumables ribbon General Control e g time date language Options Figure 4 3 Setup Page ICE Pegasus Service Manual ...

Page 56: ...rs overall print window measured in mm in the direction perpendicular to the printhead Print Orientation Allows rotation of the whole image through 180 degrees Print Delay The delay between the print signal and the commencing of the print Measured in milliseconds it allows time for the packaging film to come to a complete rest before the printhead comes in contact It should be set to the smallest ...

Page 57: ...he printer to the resistance characteristics of the printhead Printhead Setting in Continuous Mode Touch the Printhead button on the setup page to access the printhead parameters The Printhead page in continuous mode allows you to access the following parameters Print Position Changes the angle of the printhead against the target material This angle affects the print quality If the angle is not su...

Page 58: ...s you to set the following parameters Ribbon Width Sets the ribbon tension to the optimum value depending on the ribbon width narrow ribbons stretch more than wide ones and should run at lower tension Ribbon Color Allows the printer to accurately predict the end of reel condition when using the predictive end of reel detection systems Figure 4 6 Consumables Page ICE Pegasus Service Manual ...

Page 59: ...user to touch several crosses which are displayed on the screen one after the other The screen is recalibrated when the automated process is complete Note If the calibration of the machine has too many errors and does not allow a user to navigate to this screen via the CLARiTY panel the same functionality can be triggered from within CLARiTY Configuration manager Set Screen Orientation Rotates the...

Page 60: ...ith Diagnostics Touch diagnostics button on the tools page to access the diagnostics page Figure 4 8 The diagnostics page allows you to access the following pages Printhead and printing operations diagnostics Consumables ribbon diagnostics General control e g software versions communications port status diagnostics Options Figure 4 8 Diagnostics Page ICE Pegasus Service Manual ...

Page 61: ...o access the printhead diagnostics page Figure 4 9 The printhead diagnostics page allows you to access the following parameters Inputs Outputs Optics General Encoder Profiles Timings States Use the Up and Down arrow keys to navigate through the options Figure 4 9 Printhead Diagnostics Page ICE Pegasus Service Manual ...

Page 62: ...diagnostics page allows you access the following parameters Encoder Touch the encoder button to access the encoder diagnostics page The encoder diagnostic page allows you to access the following encoder parameters Figure 4 11 Figure 4 10 Printhead Inputs Diagnostics Page Figure 4 11 Encoder Diagnostics Page ICE Pegasus Service Manual ...

Page 63: ...head as parked or not Cassette Open Indicates whether the cassette home sensor is recognising the cassette as being open or closed Motor Volts Shows the voltage supply to the stepper motors must be 36V Printhead Volts Shows the drive voltage to the printhead This varies depending on the printhead resistance but should be in the range of 22V 27V depending on printhead resistance 24 Volt Supply Show...

Page 64: ... force the state of an output high or low which is useful for diagnostic purposes Printhead Position Moves the printhead from its parked to its printing position Printhead In Out Drives the air solenoid that moves the printhead in and out towards the print platen or roller External Relay and PNP Outputs The printer has 2 relay outputs and 2 PNP 24V outputs Figure 4 12 Printhead Outputs Diagnostics...

Page 65: ...and waste rolls Emitter 1 2 allows you to toggle the LED s Receiver gives a real time reading of the output High numbers of greater than 250 are read when one of the LED s are shining directly at the receiver Low numbers less than 10 are read when there is an obstruction between the LED and the receiver Test the optics by toggling each one on in turn Gain Setting is the gain applied by the electro...

Page 66: ...ive or Negative Edge Triggering Print Test Image Triggers the printing of a test image Encoder Profiling Encoder profiling is designed for continuous motion applications where there may be doubt over suitability of the application for the VJ6210 printer due to excessive linear speed or acceleration problems Encoder profiling allows the VJ6210 printer to capture the behavior of the packaging film f...

Page 67: ...ngs and the image size printed Using these values the graph shows where the print signal was received and where the print would occur within the profile as shown in Figure 4 15 This feature can be used to solve problems such as drifting print registration caused by the packaging film travelling above the maximum print speed of the printer during the registration phase Figure 4 15 Encoder Profiles ...

Page 68: ...lows you to only capture a profile if the film speed drops below the minimum limit of the printers specification On Print Signal allows you to only capture a profile after a print signal has been received Profile Type Has three options which present the information in slightly different graphical forms Choose the one which best suits your needs Profile X Axis Allows you to set the X Axis of the ch...

Page 69: ...load encoder profile to a PC proceed as follows 1 Click on the new coder icon and navigate through devices and select Capture Encoder Profile from the list as shown in Figure 4 17 2 Click on Trigger button the profile is captured in a file which is in a special encoder profile format enc Figure 4 17 Encoder Profiles CLARiTY Configuration Settings ICE Pegasus Service Manual ...

Page 70: ...s this file select Log Files folder from new coder as shown in Figure 4 18 This file can be used for diagnostic purposes by the Development Team for advanced diagnostics purposes Figure 4 18 Encoder Profiles Log Files ICE Pegasus Service Manual ...

Page 71: ... previous printing cycle Maximum speed mm s Indicates the maximum film speed during the previous printing cycle Minimum print speed mm s Indicates the actual minimum printing speed during the previous printing cycle Maximum print speed mm s Indicates the actual maximum printing speed during the last printing cycle Cycle Time ms Indicates the total time from the end of the print registration delay ...

Page 72: ...king with Consumables Diagnostics Touch Consumable button on the Diagnostics page to access to the Consumables diagnostics page Figure 4 20 The following parameters can be accessed in the consumables diagnostics page Spool 1 2 Diameters 0 1mm are the measured diameters of the ribbon and can be compared to the actual ribbon diameters after calibration to determine the accurate functioning of the ca...

Page 73: ...If there is any inconsistency among the software components that are installed in the printer the Software Part Number displays the message Incompatible Software Versions If this is seen a CLARiTY software update must be performed otherwise the coder may perform in an unpredictable manner Communications Touch this button to check the functions of the Communication Port on the printer The following...

Page 74: ...ge to access the Database page The following parameters can be access in this page Internal Shows the job stored in the printer Capacity Shows the details like the space used in the internal database and space available When an external USB memory device is connected to the printer it is accessed in the same page Figure 4 22 Database Page ICE Pegasus Service Manual ...

Page 75: ...port on the CLARiTY Operator Interface Figure 4 23 To download a job from the USB device proceed as follows 1 Copy the Image CIFF file into a root directory called jobs on the USB memory device 2 Insert the USB memory device into the USB port Figure 4 23 3 Touch the Tools button on the home page and touch Database button to access the database page Figure 4 23 Printer USB Port USB Port ICE Pegasus...

Page 76: ...he database page displays the External Database Figure 4 24 4 Touch External Database button to view all the jobs in the USB device Figure 4 25 Figure 4 24 External Database Figure 4 25 Jobs List on USB Device ICE Pegasus Service Manual ...

Page 77: ...access levels for the various operational features of CLARiTY for up to three different user groups For example the three user groups may be classified as Operators Production Supervisors and Maintenance Personnel each group requiring access to either all or a subset of the total functions of CLARiTY Protection may be globally enabled or disabled through the CLARiTY Configuration Manager The passw...

Page 78: ...hich a X appears Example Set up column in the Table 4 1 is accessible via a password only to Level 2 and Level 3 personnel Each user level has a different numeric password that can be between 4 and 10 digits Password Protection Set up Set up of password protection for CLARiTY is done using the CLARiTY Configuration Manager Run CLARiTY Configuration Manager on the PC and upload the printer paramete...

Page 79: ...iTY Configuration Manager screen to select the required options and CLARiTY Configuration Manager generates the appropriate mask number Name A name that may be optionally given to each user level as a reminder of the user group during set up of password protection Password The password required for each user access level For each level select each of these parameters in turn as shown and set them ...

Page 80: ...ler Maintaining the Printer Maintaining the Cassette Updating the CLARiTY Operating Software Warning PERSONAL INJURY Before attempting any maintenance or repair on any part of the product disconnect the printer from the main power supply and isolate the printer from any external energy sources including other connected equipment ...

Page 81: ... fuses are the only user serviceable parts in the power supply unit To replace the mains fuse proceed as follows 1 Using a small screwdriver press and turn the fuseholder anticlockwise and remove the fuseholder Figure 5 1 2 Replace the five ampere fuse if it is defective Figure 5 2 Fuseholder Figure 5 1 Fuseholder Fuse Figure 5 2 Fuse ICE Pegasus Service Manual ...

Page 82: ...e CLARiTY Controller Replacing the Power Supply Unit To open and replace the Power Supply Unit proceed as follows 1 Remove the top cover from the base of the CLARiTY Unit by unscrewing the 5 screws shown in Figure 5 3 Figure 5 3 Controller Opening 1 Screws x5 2 Top Cover 1 1 1 1 1 2 ICE Pegasus Service Manual ...

Page 83: ... CLARiTY Controller Rev AA 2 Disconnect the white power connectors from the front and back of the PSU and from the main PCB as shown in Figure 5 4 Figure 5 4 Power Connections Removal Connectors ICE Pegasus Service Manual ...

Page 84: ...ical connectors are securely pushed into place Replacing the CLARiTY Processor PCB and LCD Touchscreen Assembly In order to replace the CLARiTY Processor PCB or the LCD Touchscreen Assembly remove the top cover as described in the section Replacing the Power Supply Unit on page 5 3 Then follow the additional procedure below 1 Remove the power connector from the main PCB Screws Figure 5 5 Base Scre...

Page 85: ...ring screws from the D type connectors on the bottom of the CLARiTY unit Figure 5 6 3 Carefully remove the three connectors from the PCB taking care not to bend or twist the cables Figure 5 6 D Type Securing Screws Figure 5 6 Top Case Detail ICE Pegasus Service Manual ...

Page 86: ... the LCD Touchscreen module If replacing the Processor PCB then refer to section 13 below If replacing the LCD Touchscreen Assembly then continue below Replacing the LCD Touchscreen Assembly 6 Remove and retain the three screws and anti vibration washers holding the whole assembly and inverter module Remove this module from the case taking care not to remove the seal around the Figure 5 7 PCB Conn...

Page 87: ...ev AA case aperture Figure 5 8 7 Disconnect the backlight power cable white pink connection 8 Remove and retain the four screws holding the LCD touchscreen assembly to the metal support plate Figure 5 8 PCB Removal ICE Pegasus Service Manual ...

Page 88: ...new LCD touchscreen assembly face down on a clean soft surface and fit the support plate using the four screws removed earlier Ensure that the touchscreen signal ribbon cable is carefully routed through the slot in the base plate without damage Figure 5 10 Figure 5 9 Separated LCD Assembly Figure 5 10 Touch Screen Ribbon Cable Routing ICE Pegasus Service Manual ...

Page 89: ...r cable and re fit the three securing screws and the anti vibration washers 13 Refit the Processor PCB with its two securing screws again taking care not to trap the backlight power cable 14 Refit the three connectors to the PCB and the securing screws for the D type connections 15 Refit the power connector 16 Replace the Top cover over the base and secure with the five screws on the sides Figure ...

Page 90: ... Printhead The Cassette Rollers Replacing the Compact Flash Card To replace the compact flash card proceed as follows 1 Remove the cassette and place the printer face down on a flat surface Remove the rear cover by unscrewing the 4 screws one from each side of the printer Figure 5 12 and then lift the cover off Figure 5 12 Rear Cover Removal 1 Screws 1 1 1 1 ICE Pegasus Service Manual ...

Page 91: ...new card orientate such that the face with the Windows License sticker is facing away from the PCB and gently but firmly push home 4 Replace the rear cover Replacing the Main PCB To replace the main PCB proceed as follows 1 Before removing the rear cover place the printer on a flat surface cassette side up and remove the cassette if this hasn t already been removed Windows License Sticker Figure 5...

Page 92: ...over as detailed above in the section Replacing the Compact Flash Card on page 5 11 4 Next remove the nuts securing the D Type connectors to the side plate still secured to the unit Figure 5 15 Screws Figure 5 14 Cassette Screws Removal Figure 5 15 D Type Securing Nuts Nuts ICE Pegasus Service Manual ...

Page 93: ...ly withdraw the PCB including the 15way D Type connector for the I O connections Figure 5 16 7 Remove and retain the I O connection ribbon cable 8 To replace the PCB firstly insert and secure the I O D Type connector to the side plate Figure 5 17 Figure 5 16 Main PCB Removed I O Connection Cable Figure 5 17 Main PCB Replacement I O D Type Connector ICE Pegasus Service Manual ...

Page 94: ...ector X9 is threaded through the access hole in the heat sink Figure 5 18 10 Secure the PCB using the 2 screws and then reverse the procedure from 5 to 1 above Replacing the Peel Roller To replace the peel roller proceed as follows 1 Remove the cassette from the printer Figure 5 18 X9 Connector Access ICE Pegasus Service Manual ...

Page 95: ...shown in Figure 5 19 3 Remove the peel roller 4 Replace the peel roller and secure it using the screw removed in step 2 5 Refit the cassette to the printer Figure 5 19 Peel Roller Screw Removal 1 Peel Roller 2 Screw 1 2 Figure 5 20 Peel Roller Removal Peel Roller ICE Pegasus Service Manual ...

Page 96: ...thead proceed as follows 1 Remove the printhead retaining screw as shown in Figure 5 21 2 Move the printhead from the parked position 3 Disconnect the printhead and remove Printhead Screw Figure 5 21 Printhead Screw Removal Figure 5 22 Printhead Removal ICE Pegasus Service Manual ...

Page 97: ...t printhead resistance Caution PRINTHEAD RESISTANCE If the printhead is changed the new printhead resistance must be set If not set correctly damage could occur to the printhead or poor quality images could result Such damage is not covered by your printer warranty To set the printhead resistance proceed as follows 1 Find and note the printhead resistance value from the label on the printhead e g ...

Page 98: ... the settings and touch OK to save the settings 7 A confirmation message is displayed to ensure that this parameter is not changed inadvertently Choose Yes to proceed to set the new value Maintaining the Cassette Replacing the Cassette Rollers To replace the cassette rollers proceed as follows 1 Remove the cassette from the printer 2 Remove the ribbon from the cassette Figure 5 24 Printhead Resist...

Page 99: ...ure 5 25 4 Remove the roller from the ribbon guide as shown in Figure 5 26 5 Place the new roller on the ribbon guide 6 Install the ribbon guide on the cassette 7 Replace the ribbon in the cassette 8 Replace the cassette in the printer Figure 5 25 Roller Guide Removal Roller Figure 5 26 Roller Removal ICE Pegasus Service Manual ...

Page 100: ...ry and normally do not require adjustment If it is necessary to adjust the latch proceed as follows 1 Remove the cassette from the printer 2 Remove any ribbon from the cassette 3 Loosen the lock nut on the cassette latch 10 mm as shown in Figure 5 27 Figure 5 27 Latch Screw Locking Nut Loosening ICE Pegasus Service Manual ...

Page 101: ... the lock nut as shown in Figure 5 28 Note A correctly adjusted latch should not allow the movement of the cassette when in the printer but should allow the cassette to be pulled from the printer under any circumstances when the release button is pressed Figure 5 28 Latch Screw Adjustment ICE Pegasus Service Manual ...

Page 102: ...e unpredictable printer behavior may result The printer should be used only when a valid part number is displayed in the part number window There are two ways of performing a CLARiTY Update 1 Connecting the printer to a PC that runs CLARiTY Configuration manager 2 Inserting a USB memory stick containing the update file into the printer Before performing a CLARiTY Update it is strongly recommended ...

Page 103: ...nd the CLARiTY screen indicates the progress of the update Note It is very Important to ensure that the power to the printer is not removed during the update process or the flash card in the printer may get corrupted When the update is finished CLARiTY automatically re boots and the CLARiTY Home Screen is finally displayed 6 Check the Software Part number in the Diagnostics screen to ensure that t...

Page 104: ...ct the stick to the CLARiTY Operator Interface via the USB port as shown in Figure 5 30 3 If the CLARiTY Configuration Manager parameter called Prompt On CLARiTY Update Detect is set to Yes when the device is connected to the CLARiTY Operator Interface a confirmation page is displayed Figure 5 31 Figure 5 30 USB Location USB Port Figure 5 31 Confirmation Page ICE Pegasus Service Manual ...

Page 105: ...L and touch the CLARiTY Update button 5 Select Yes to proceed to the next stage of the update or No to return to the Home screen If Yes is selected the CLARiTY update screen is displayed Only updates applicable to the current model of printer are displayed Figure 5 32 CLARiTY Update Page ICE Pegasus Service Manual ...

Page 106: ...that the power to the printer is not removed during the update process or the flash card in the printer may get corrupted When the update is finished CLARiTY automatically re boots and the CLARiTY Home Screen is finally displayed 8 Check the Software Part number in the Diagnostics screen to check that the update has been successful Figure 5 33 CLARiTY Confirmation Page ICE Pegasus Service Manual ...

Page 107: ...me Clock Fault There is a problem with the real time clock which is required for the system to operate correctly Fault E1004 Backup Battery is Flat The battery which powers the printer s clock is flat This means that the date and time the currently selected job and some performance data is lost when the printer is switched off Warning E1006 Image Update Failure CLARiTY is unable to update the imag...

Page 108: ...and the printer body Fault E3009 Bad Optical Calibration Ribbon cores are of incor rect size Fault E3010 Thermistor Fault Printer has detected fault with the thermistor or the thermistor is disconnected Fault E3011 Printhead Over Temperature Coder operating over 65 degrees Celsius Fault E3012 Low Ribbon Less than 50 metres of ribbon left on the reel Warning E3013 Printhead Absent Communications be...

Page 109: ...nded by the control system If the Clear button is available below you may touch it to clear this error and resume printing Fault E1100 Invalid Job File Bad Field Reference Source field reference incorrect correct in CLARiSOFT Warning E1101 Invalid Job File Missing Data Source Field Job file missing a data field correct in CLARiSOFT Warning E1102 Invalid Job File Duplicate Named Fields Field names ...

Page 110: ... causes and the remedies Error Message Possible Causes Remedies Cassette Open Cassette not fully seated Push the cassette in until you hear it click into place Cassette latch out of adjustment Adjust the cassette latch Faulty cassette sensor Replace the printhead sensor Home switch magnet missing from the cassette base plate Replace the magnet Table 7 1 Error Messages and Remedies 7 ...

Page 111: ...all the ribbon Host machine is holding the ribbon firmly Review and correct the application Calibration Failed Ribbon installed incorrectly Reinstall the ribbon Ribbon reel diameter is out of range Use correct ribbon reel Damaged cassette Check for the damaged cassette base plate giving misaligned drive or ribbon tracking problems usually this results when a cassette is dropped from a height onto ...

Page 112: ... the calibration sensor Remove the tag Thermistor Fault Faulty printhead Replace the printhead Ribbon cable has loosened Push the ribbon back into place Faulty printhead ribbon cable Replace the printhead ribbon cable Printhead Over Temperature Printhead overheats Allow the printhead to cool down Low Ribbon Ribbon has to be replaced Replace the ribbon Printhead Absent Loss of communication between...

Page 113: ...ibration Required Flash memory is lost Use the CLARiTY configuration CD Printhead Resistance Not Set Flash memory is lost Set the resistance value from the user interface Webbing Error Supply ribbon reel eccentric 1mm Replace the reel End of Reel Less than 20 meters of ribbon remaining on reel Replace the reel Incorrect Reel Size Ribbon cores not fitted Try using a different reel Incorrect roll wi...

Page 114: ...operly connected to the printer and controller Check and correct Incorrect cable between the printer and controller Check and correct Faulty controller unit Check unit and replace the components as required Printhead does not move in and out Air supply disconnected Check and set air pressure to 3 bar Solenoid wiring or air lines defective Check and correct Defective solenoid Check and correct Prin...

Page 115: ... correct Linear slide carriage jammed Turn the power off Try to move the linear slide If jammed clear the obstruction Incorrect tension on the timing belt Re tension the timing belt Faulty Motor Check the motor and replace it if necessary Error Message Possible Causes Remedies Table 7 1 Error Messages and Remedies Continued ICE Pegasus Service Manual ...

Page 116: ...uld be about 2100 for right hand units 2500 for left hand units Intermittent Mode Only Substrate is moving while attempting to print Print signal timing is incorrect If necessary delay the print until the film stops and settles Dwell Time by entering a Print Delay value Go to Tools Setup Printhead Intermittent Mode Only Incorrect Print Speed Go to Tools Setup Printhead Check and correct the print ...

Page 117: ...ation Continuous Mode Only Incorrect Print Position parameter Go to Tools Setup Printhead and check the print position to ensure optimum printhead position directly over roller centerline Parameter should be about 2100 for right hand units 2500 for left hand units Intermittent Mode Only Substrate is moving while attempting to print Print signal timing is incorrect If necessary delay the print unti...

Page 118: ...ls Setup Printhead Intermittent Mode Only Incorrect Horizontal Registration setting Check and correct One or more dots missing cleaning does not help Faulty Printhead Replace the Printhead Ribbon is creasing Poor alignment of printer to platen or roller Correct the alignment with the shims between the printer and bracket or behind the platen Bent peel roller shaft or support Check and replace if n...

Page 119: ...e items and the modules for which the part numbers are given How to Read the IPL This section describes how the higher assemblies are broken down to their related subassemblies and other separate parts Illustrations Table 8 1 shows the symbols used to indicate the different levels of main assemblies in a printer and the subassemblies under the main assembly The arrow indicates further explosion of...

Page 120: ...e alphabets assigned to main assemblies are used only for one time The alphabets I and O are not used because you can read the alphabets incorrectly as the numbers 1 and 0 Numbers A natural number 1 2 3 is assigned to the standalone parts in the increasing order in the chapter See Figure 8 1 Note The numbers assigned to main assemblies are used only for one time Figure 8 1 Graphical Representation...

Page 121: ... explosion of the main assemblies in the parts lists Item Number P N Description Qty A 1 2 3 4 5 6 B 7 8 D 9 10 C 11 12 13 14 Table 8 2 Representation of the different Subassemblies and parts in the Table Main Assembly Subassembly 1 Main Assembly Main Assembly ICE Pegasus Service Manual ...

Page 122: ...A Controller Assembly Refer to Figure 8 2 1 400885 Thermal Coder Fuse Kit Set of 10 2 403348 Power Supply Unit 1 3 403345 Processor PCB 1 4 403344 LCD Touchscreen 1 5 403183 Controller Mounting Yoke Kit 1 6 402793 Thermal Printer Mains Lead Assembly 1 Table 8 3 Controller Assembly Parts List 2 1 3 4 5 Figure 8 2 Controller Assembly A 6 ...

Page 123: ...6210 Service Manual Rev AA Printer Assembly 8 5 Printer Assembly Printhead Assembly Figure 8 3 Printer Assembly 8 7 D B Printer Assembly with PCB Printer Assembly without PCB Figure 8 4 Printhead Assembly 9 10 D ...

Page 124: ... Number P N Description Qty B Printer Assembly Refer to Figure 8 3 on page 8 5 7 403332 Videojet 6210 Thermal Printer PCB 1 8 403339 Thermal Printer 128mb Flash Card 1 D Printhead Assembly Refer to Figure 8 4 on page 8 5 9 403325 Thermal Printhead 1 10 403324 Peel Roller 5 off Table 8 4 Parts of Printer Assembly ...

Page 125: ...sembly Item Number P N Description Qty C Cassette Assembly Refer to Figure 8 5 11 403327 Silver Disc Pack 5 off 12 403323 53mm Cassette Roller Set of 6 13 Print Ribbon Refer to Table 8 7 on page 8 9 for details 14 403326 Black Disc Pack 5 off Table 8 5 Parts of Cassette Assembly Figure 8 5 Cassette Assembly 11 12 13 14 C ...

Page 126: ...N Description Qty 1 403357 Spare 32T Bracket Platen Rubber Continuous Pack of 10 2 403357 Spare 32T Bracket Platen Rubber Intermittent Pack of 10 3 401339 Spare Encoder O ring Pack of 10 4 403318 Intermittent Bracket Assembly 1 5 403317 Continuous Bracket Assembly 1 Table 8 6 Accessories List Figure 8 6 Accessories 1 2 3 4 5 ...

Page 127: ...inter Serial Number Part Number Description 1 702305 Standard Black 20mm x 600m 2 702304 Standard Black 35mm x 600m 3 Standard White 20mm x 450m 4 Standard White 35mm x 450m 5 Premium Black 20mm x 550m 6 Premium Black 35mm x 550m 7 Premium White 20mm x 550m 8 Premium White 35mm x 550m Table 8 7 Printer Ribbons ...

Page 128: ...0 3 Places 20 73 mm 2 PLCS 167 15 mm 185 30 mm 158 00 mm Printhead Retracted 162 50 mm 25 70 mm 32 50 mm 1 28 inches 157 80 mm 159 60 mm 26 20 mm 32 00 mm Printable Area Figure 9 1 Videojet 6210 30 mm RH Printer Dimensions 7 3 inches 6 58 inches 164 00 mm 6 46 inches 1 01 inches Printhead Stroke 6 4 inches 6 22 inches 6 23 inches 6 21 inches 1 03 inches 1 26 inches 2 54 inches 0 57 inches 0 82 inc...

Page 129: ...0 73 mm 2 PLCS 70 73 mm 2 78 inches M6 Tapped Holes Thread Depth 6 00 3 Places 164 00 mm 167 15 mm 185 30 mm Printhead Retracted 162 50 mm 158 00 mm 29 0 mm 157 80 mm 159 60 mm 32 00 mm Printable Area 32 50 mm 1 28 inches 26 20 mm 7 29 inches 0 57 inches 2 54 inches 0 82 inches 6 58 inches 6 46 inches 6 22 inches 6 39 inches 1 14 inches Printhead Stroke 6 28 inches 6 21 inches 1 03 inches 1 26 inc...

Page 130: ... 9 3 shows the dimensions of the CLARiTY controller Figure 9 3 CLARiTY Controller Dimensions 69 20 mm 208 35 mm 191 25 mm 41 00 mm M6 Female Thread Both Sides Thread Depth 6 00 96 90 mm 118 90 mm 4 68 inches 8 2 inches 7 53 inches 3 81 inches 2 72 inches 1 61 inches ...

Page 131: ... CLARiTY Board and Inverter X8 X9 X2 X13 X1 5W HDR 1 25 mm X5 4 way FFC RJ11 6pin 20 way FFC 503291 14W HDR SIL 0 1 inch 8W Molex MiniFit Optional Ethernet RS 232 Board 603305 CLARiTY Board 603105 USB A 9W D RJ45 25W D 9W D 9W D X11 X15 X16 X6 X3 X14 Memory Stick RS 232 Comm s Option Ethernet Option Printer Data Printer Power RS 232 Comm s S1 FUI P1 Mains Power Switch I O Mains Fuse Mains Inlet T5...

Page 132: ...sh 6W Molex 0 1 inch 2W Molex 0 1 inch 3W Molex 0 1 inch 2W Molex 0 1 inch M M M1 M2 M3 503297 503297 Printer Control Board 603052 X9 X14 X1 Detector PCB 603112 6W Molex 0 1 inch 6W Molex 0 1 inch X16 34W IDC Printhead Cable LH 503265 or RH 503271 2W JST 2 5 mm 26W IDC 2W Molex 0 1 inch Thermal Printhead 103120 Head Park Micro switch 503295 503290 X11 X6 37W D Plug X21 15W D Plug CLARiTY Connector...

Page 133: ...put 1 Fault relay COMMON 8 Red Black External relay output 1 Fault relay N O 9 Green Black External relay output 2 Warning relay COMMON 10 Orange Black External relay output 2 Warning relay N O 11 Blue Black External PNP output 3 PNP 24V BUSY 12 Black White Black on ENC 0V 0V 13 Red White External PNP Output 4 PNP 24V Spare not used 14 Green White White on ENC lead Encoder phase B signal input 24V...